Body support with non-planar top surface

ABSTRACT

A body support including a visco-elastic foam layer having a length and a non-planar top surface with peaks and troughs that define a horizontal distance between peaks and a vertical height between a peak and a trough. The peaks and troughs of the non-planar top surface form sinusoidal or domed waves. A density of the foam at the peaks is substantially the same as the density of the foam at the troughs. A ratio of the length to the distance is from 10 to 50, optionally from 15 to 40. The ratio of length to distance can be from 20 to 30 and optionally from 20 to 25.

CROSS-REFERENCE TO RELATED APPLICATIONS

Priority is hereby claimed to U.S. Provisional Patent App. No. 61/140,721, filed Dec. 24, 2008, and U.S. Provisional Patent App. No. 61/142,777, filed Jan. 6, 2009, the entire contents of both of which are herein incorporated by reference.

BACKGROUND

Conventional body supports are found in a wide variety of shapes and sizes, each of which is adapted for supporting one or more body parts of a user. As used herein, the term “body support” includes without limitation any deformable element or structure adapted to support one or more parts of (or the entire body of) a human or animal in one or more positions. Examples of body supports include but are not limited to mattresses, pillows, and cushions of any type, including those for use in beds, seats, and other applications.

Body supports are often constructed entirely or partially out of foam material. For example, polyurethane foam is commonly used in many mattresses, pillows, and cushions, and can be used alone or in combination with other types of cushion materials. In many body supports, visco-elastic material is used, providing the body support with an increased ability to conform to a user and to thereby distribute the weight or other load of the user. Some visco-elastic body support materials are also temperature sensitive, thereby also enabling the body support to change firmness based at least in part upon the temperature of the body part(s) supported thereon.

In addition to the increasing use of visco-elastic foams in body supports, reticulated foams (both visco-elastic and non-visco-elastic) have also gained in popularity. Reticulated foams can provide added benefits of increased heat and moisture transfer due in large part to the relatively porous nature of reticulated foams. These characteristics are often highly desirable in body support applications of all types.

Although the number and types of body supports constructed with one or more layers of foam continue to increase, including one or more layers of foam comprising visco-elastic foam and/or reticulated foam, the capabilities of such materials are often underutilized. In many cases, this underutilization is due to poor body support design and/or the choice of material(s) used in the body support.

Based at least in part upon the limitations of existing body supports and the high consumer demand for improved body supports in a wide variety of applications, new body supports continue to be welcome additions to the art.

SUMMARY OF THE INVENTION

Some embodiments of the present invention provide a body support having a layer of foam material adapted for use as the upper-most surface of the body support and having a top surface and a bottom surface, wherein the top surface of the body support is a non-planar surface defined at least in part by a series of waves extending across at least part of the length or width of the body support and having dimensions selected to visually communicate softness of the body support and/or to simulate a billowy user body support surface. In some embodiments, the body support includes visco-elastic foam and/or comprises reticulated foam. The body support can itself have two or more layers, the top layer of which has the non-planar surface. Also, the body support can be adapted for use alone or in combination with one or more underlying body support layers, any of which can include foam of any type (e.g., visco-elastic or non-visco-elastic, reticulated or non-reticulated, and the like), and which can be permanently or releasably attached to the body support, or which can support the body support without being attached thereto.

Some embodiments of the invention provide a body support including a visco-elastic or other foam layer having a length and a non-planar top surface with peaks and troughs that define a horizontal distance between peaks and a vertical height between a peak and a trough. The peaks and troughs of the non-planar top surface form sinusoidal or domed waves. A density of the foam at the peaks is substantially the same as the density of the foam at the troughs. A ratio of the length to the distance can be from 10 to 50, optionally from 15 to 40. The ratio of length to distance can be from 20 to 30 and optionally from 20 to 25.

Some embodiments of the invention provide a body support including a visco-elastic or other foam layer having a length and a non-planar top surface with peaks and troughs that define a horizontal distance between peaks and a vertical height between a peak and a trough. The peaks and troughs of the non-planar top surface form sinusoidal or domed waves. A ratio of the distance to the height is from 13 to 66 or optionally from 20 to 52. The ratio of the distance to the height can be from 26 to 40 and can optionally be from 26 to 33. A density of the foam at the peaks is substantially the same as the density of the foam at the troughs.

Further aspects of the present invention, together with the organization and operation thereof, will become apparent from the following detailed description of the invention when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a body support according to an embodiment of the present invention.

FIG. 2 is a perspective view of a body support according to another embodiment of the present invention.

FIG. 3 is a side view of a portion of the body support of FIG. 2.

DETAILED DESCRIPTION

Before the various embodiments of the present invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, terms such as “first”, “second”, and “third” are used herein and in the appended claims for purposes of description and are not intended to indicate or imply relative importance or significance unless otherwise specified. The term “first” does not necessarily refer to the top most layer, rather, it refers to the first of a plurality, without indicating a particular location or position. Similarly, the terms “top” and “bottom” are used for the purpose of description and are not intended to indicate or imply relative importance, significance, unless otherwise specified. The term “top” does not necessarily refer to the top most layer, and “bottom” does not necessarily refer to the bottom most layer.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and variations thereof herein are used broadly and encompass direct and indirect connections and couplings. In addition, the terms “connected” and “coupled” and variations thereof are not restricted to physical or mechanical connections or couplings.

Body supports 10 according to two different embodiments of the present invention are illustrated schematically in FIGS. 1-3. Both illustrated body supports 10, 10A are defined by one or more layers of foam material adapted to be used alone (e.g., on a floor, frame, or other structure) or upon another body support (e.g., a mattress). In both applications, the body supports 10, 10A define the top layer(s) of a body support upon which a user lies. Accordingly, each of the body supports 10, 10A can itself define a mattress (e.g., a futon), can be part of a mattress (i.e., define the uppermost layer(s) or pillow top of a mattress that has one or more underlying layers), or can define a mattress topper or overlay intended either for releasable attachment to an existing mattress or for resting upon an existing mattress without being attached thereto, depending upon the manner in which the body support 10, 10A is used. However, it will be appreciated that the features of the body supports 10, 10A described and/or illustrated herein are applicable to any other type of body support having any size and shape. Accordingly, as used herein, the term “body support” is intended to refer to any and all of such structures, unless otherwise specified.

The body support 10 illustrated in FIG. 1 includes a top surface 12 positioned to face and support a user thereon, and a bottom surface 14 adapted to either rest directly upon a floor surface, frame, foundation, or other rigid support, or upon another body support or portion of a body support. In the illustrated embodiments of FIGS. 1-3, the top surface 12, 12A is substantially non-planar and the bottom surface 14 is substantially planar. In other non-illustrated embodiments, either or both of the top and bottom surfaces 12, 14 can include one or more convolutions or other non-planar shapes.

The body support 10 includes a layer of foam material defining the uppermost (non-planar) surface of the body support 10, and can have one or more additional layers (not shown) immediately beneath the layer of foam. In this regard, the body support 10 can be manufactured of any type of foam, including without limitation visco-elastic and non-visco-elastic foam, reticulated and non-reticulated foam, polyurethane foam, latex foam, any expanded polymer (e.g., expanded ethylene vinyl acetate, polypropylene, polystyrene, or polyethylene), and the like. If the body support 10 is defined by two or more layers of material, the layer(s) beneath this uppermost layer can also be manufactured of any type of foam (including those mentioned above), any other type of body support material, and any combination of these materials. In some embodiments, the resulting body support of two or more layers can be a single integral unit permanently attached together in any conventional manner (e.g., by adhesive or cohesive bonding material, by being bonded together during formation of the layers, by stitches extending at least partially through the layers, or in any other suitable manner).

By way of example only, the foam of the body supports 10, 10A shown in FIGS. 1-3 is non-reticulated visco-elastic foam, sometimes referred to as “memory foam” or “low resilience foam”. As mentioned above, in other embodiments, the foam of the body support 10, 10A can comprise reticulated visco-elastic foam, or reticulated or non-reticulated non-visco-elastic foam. Reticulated foam (visco-elastic or otherwise) is a cellular foam structure in which the cells of the foam are essentially skeletal. In other words, the cells of the reticulated foam are each defined by a plurality of apertured windows surrounded by cell struts. The cell windows of reticulated foam can be entirely gone (leaving only the cell struts) or substantially gone. In some embodiments, the foam is considered “reticulated” if at least 50% of the windows of the cells are missing (i.e., windows having apertures therethrough, or windows that are completely missing and therefore leaving only the cell struts). Such structures can be created by destruction or other removal of cell window material, or preventing the complete formation of cell windows during the manufacturing process of the foam.

The visco-elastic nature of the foam material of the body supports 10, 10A illustrated in FIGS. 1-3 can provide a relatively soft and comfortable substrate for a user's body or body portion (hereinafter referred to simply as “body” for ease of description). Also, by its nature, the visco-elastic foam body supports 10, 10A at least partially conforms to the user's body to distribute force applied thereby. By virtue of the low-resiliency and pressure-distributing characteristics of visco-elastic foam, the non-planar surface of the illustrated visco-elastic body supports 10, 10A (described in greater detail below) will not result in discomfort to a user, as the non-planar surface will conform to the user's body with minimal to no resistance. Accordingly, the top surface 12, 12A of the visco-elastic body support 10, 10A can be made non-planar to perform the functions described below while not sacrificing the function of properly supporting the user.

In some embodiments, the visco-elastic foam of the body support 10, 10A has a hardness of at least about 30 N and no greater than about 175 N for desirable softness and body-conforming qualities. In other embodiments, the visco-elastic foam of the body support 10, 10A has a hardness of at least about 40 N and no greater than about 110 N for this purpose. In still other embodiments, the visco-elastic foam of the body support 10, 10A has a hardness of at least about 40 N and no greater than about 75 N. Unless otherwise specified, the hardness of a material referred to herein is measured by exerting pressure from a plate against a sample of the material having length and width dimensions of 40 centimeters (cm) each (defining a surface area of the sample of material), and a thickness of 5 cm to a compression of 40% of an original thickness of the material at approximately room temperature (e.g., 21-23 Degrees Celsius), wherein the 40% compression is held for a set period of time following the International Organization of Standardization (ISO) 2439 hardness measuring standard.

The visco-elastic foam of each illustrated body support 10, 10A can also have a density providing a relatively high degree of material durability. The density of the visco-elastic foam of each illustrated body support 10, 10A can also impact other characteristics of the foam, such as the manner in which the body support 10, 10A responds to pressure and the feel of the foam. In some embodiments, the foam of the body support 10, 10A is visco-elastic, and has a density of no less than about 30 kg/m³ and no greater than about 175 kg/m³. In other embodiments, this body support foam has a density of at least about 40 kg/m³ and no greater than about 130 kg/m³. In still other embodiments, this body support foam has a density of at least about 55 kg/m³ and no greater than about 115 kg/m³.

With continued reference to the visco-elastic foam body supports 10, 10A illustrated in FIGS. 1-3, the visco-elastic foam of the body supports 10, 10A can be selected for responsiveness to any range of temperatures. However, in some embodiments, a temperature responsiveness in a range of a user's body temperatures (or in a range of temperatures to which the body support 10, 10A is exposed by contact or proximity to a user's body resting thereon) can provide significant advantages. For example, a visco-elastic foam selected for the body support 10, 10A can be responsive to temperature changes above at least about 10° C. In other embodiments, the visco-elastic foam selected for the body supports 10, 10A can be responsive to temperature changes within a range of at least about 15° C. As used herein, a material is considered “responsive” to temperature changes if the material exhibits a change in hardness of at least 10% measured by ISO Standard 3386 through the range of temperatures between 10 and 30 degrees Celsius.

As discussed above, either body support 10, 10A can be constructed of reticulated foam (visco-elastic or otherwise), rather than the non-reticulated visco-elastic foam just described. In such embodiments, airflow characteristics of the reticulated foam can be significantly different, as can the material characteristics of the reticulated foam. More detail regarding the features and characteristics (e.g., hardness, density, and temperature sensitivity) of reticulated foam used in some embodiments of the present invention is presented below.

By virtue of the skeletal cellular structure of reticulated foam, body supports 10, 10A comprising such foam are able to transfer heat away from a source of heat (e.g., a user's body) on the body support 10, 10A, thereby helping to prevent one or more areas of the body support 10, 10A from reaching an undesirably high temperature. Also, the reticulated structure of the foam enables significantly higher airflow into, out of, and through the body support 10, 10A—a characteristic of the body support 10, 10A that can reduce heat in the body support. Furthermore, the reticulated structure of the foam can function as a wick, drawing moisture from an exterior area of the body support 10, 10A (e.g., adjacent the user's body thereon) to locations away from the user's body, thereby increasing user comfort. At the same time, in those embodiments in which the body support 10, 10A comprises reticulated visco-elastic foam, the visco-elastic nature of the foam provides desirable tactile contact and pressure responsiveness for user comfort. In this regard, reticulated visco-elastic foam of some embodiments can have a reduced hardness level, thereby providing a relatively soft and comfortable surface for a user's body. In conjunction with the slow recovery characteristic of the reticulated visco-elastic material, the body support 10, 10A can also at least partially conform to the user's body, thereby distributing the force applied by the user's body upon the body support 10, 10A.

In some embodiments, the body support 10, 10A of reticulated visco-elastic foam has a hardness of at least about 20 N and no greater than about 150 N for desirable softness and pressure-responsive qualities. In other embodiments, a body support 10, 10A having a hardness of at least about 30 N and no greater than about 100 N is utilized for this purpose. In still other embodiments, a body support 10, 10A having a hardness of at least about 40 N and no greater than about 85 N is utilized.

Body supports 10, 10A manufactured from reticulated visco-elastic foam can also have a density providing a relatively high degree of material durability. The density of the reticulated visco-elastic foam can also impact other characteristics of the foam, such as the manner in which the body support 10, 10A responds to pressure, and the feel of the foam. In some embodiments, the reticulated visco-elastic foam of the body support 10, 10A has a density of no less than about 30 kg/m³ and no greater than about 175 kg/m³. In other embodiments, the reticulated visco-elastic foam of the body support 10, 10A has a density of at least about 45 kg/m³ and no greater than about 130 kg/m³. In still other embodiments, the reticulated visco-elastic foam of the body support 10, 10A has a density of at least about 50 kg/m³ and no greater than about 120 kg/m³.

In those body support embodiments in which the body support 10, 10A is manufactured from reticulated visco-elastic foam, the reticulated visco-elastic foam can be selected for responsiveness (as defined above) to any range of temperatures, including those described above.

As shown in FIGS. 1-3, the top surface 12, 12A of both body supports 10, 10A is non-planar, and includes a plurality of peaks 16, 16A and troughs 18, 18A defining a wave-shaped top surface 12, 12A of the body support 10, 10A. In some embodiments, the peaks 16, 16A and troughs 18, 18A are regularly spaced along the body support 10, 10A. However, in other embodiments, the peaks 16, 16A and troughs 18, 18A are irregularly spaced.

The peaks 16, 16A and troughs 18, 18A of the body supports 10, 10A can be defined by a number of different wave shapes, including the domed waves shown in FIG. 1 and the sinusoidal waves shown in FIGS. 2 and 3. In both examples, the wave shape of the body supports 10, 10A is selected to visually communicate softness of the body support 10, 10A and/or to simulate a billowy user body support 10, 10A, both of which are desirable attributes for many users. Other wave shapes are capable of performing the same functions, and fall within the spirit and scope of the present invention.

The following description is presented in connection with the embodiment of FIGS. 2 and 3, it being understood, however, that this description applies equally to the embodiment of FIG. 1. Factors that can be important to visually communicate softness of the body support 10A and/or to simulate a billowy user body support 10A can include the distance D between adjacent peaks 16A in a body support 10A, the height of the peaks 16A (measured from trough 18A to peak 16A, or the difference between H2 and H1 in FIG. 3), and the ratio of these values (e.g., D:(H2-H1)). In some embodiments, the distance D between adjacent peaks 16A is no less than about 260 mm and is no greater than about 660 mm to perform the visual communication and simulation functions described above. In other embodiments, this distance D is no less than about 400 mm and is no greater than about 520 mm to perform these functions.

Also, in some embodiments, the peak height (H2-H1) is no less than about 10 mm to perform the visual communication and simulation functions described above. In other embodiments, this peak height is no less than about 20 mm to perform these functions.

A ratio of the distance D to the peak height (H2-H1) is from 13 to 66 or optionally from 20 to 52. The ratio of the distance to the height can be from 26 to 40 and can optionally be from 26 to 33.

As indicated above, in some embodiments, the distance D between adjacent peaks 16A may vary such that the distance D is different along one portion of the body support 10A when compared to the distance D along another portion of the body support 10A. This may be especially advantageous if the body support 10A is configured to support bodies exerting different pressures at different locations on the body support 10A. Similarly, in some embodiments, the peak height (H2-H1) may vary along the body support 10A such that the peak height (H2-H1) along one portion of the body support 10A is different when compared to the peak height (H2-H1) along another portion of the body support 10A.

As described above, the top surface 12, 12A of the body supports 10, 10A are configured to visually communicate softness and to simulate a billowy body support 10, 10A. As also described above, this is accomplished by shaping the top surface 12, 12A to have peaks 16, 16A and troughs 18, 18A. This shaping can be performed by directly forming the foam of the body support 10 (rather than, for example, by using quilting techniques), such as by cutting a slab of foam to have the peaks 16, 16A and troughs 18, 18A, by molding foam to have such peaks 16, 16A and troughs 18, 18A, and by other manufacturing methods. In some embodiments, the density of the foam at the peaks 16, 16A and the density of the foam at the troughs 18, 18A is substantially similar, and in some embodiments is identical.

The plurality of peaks 16, 16A and troughs 18, 18A in the illustrated embodiments of FIGS. 1-3 extend across the width of the body supports 10, 10A, and run in succession along the length of the body supports 10, 10A. In other embodiments, the non-planar surface can be formed from a plurality, and in some cases a pattern, of such projections extending orthogonally with respect to the direction shown in FIGS. 1-3 (i.e., peaks 16, 16A and troughs 18, 18A extending along the length of the body support 10, 10A, and running in succession along the width of the body support 10, 10A). Still other directions in which the peaks 16, 16A and troughs 18, 18A can run are possible, and fall within the spirit and scope of the present invention.

In the illustrated embodiments of FIGS. 1-3, the non-planar top surface 12, 12A of each body support 10, 10A is uniform across the width and length of the body support 10, 10A. However, in other embodiments, the non-planar top surface 12, 12A may not extend fully across the length and/or width of the body support 10, 10A. Also, the non-planar top surface 12, 12A may not be uniform across the full width and length of the body support 10, 10A, but can instead also include a combination of peaks, troughs, waves, bumps, and/or other projections and recesses extending across the whole width and length, or alternatively across only a portion of the width and/or length of the body support 10, 10A. Accordingly, there may be one or more portions of the top surface of the body support 10, 10A which are planar.

With continued reference to the illustrated embodiments of FIGS. 1-3, the top surfaces 12, 12A of both embodiments are shown as having five peaks 16 and four troughs 18. However, in other embodiments, these top surfaces can have less or more than five peaks and four troughs. For example, some mattress-type body supports according to the present invention utilize no fewer than two peaks and no greater than ten peaks across the length L of the body support 10. In other mattress-type body support embodiments, no fewer than four peaks and no greater than six peaks are used across the length L of the body support 10. In still other mattress-type body support embodiments, no fewer than four peaks and no greater than five peaks are used across the length L of the body support 10. In some desirable embodiments, the mattress-type body support 10 has four peaks used to convey the visual impression of proper user support in particular areas of the body support 10 (e.g., head, back, buttocks, and legs).

A ratio of the length L of the body support 10 to the distance D between adjacent peaks 16A can be from 10 to 50, optionally from 15 to 40. The ratio of length to distance can be from 20 to 30 and optionally from 20 to 25.

The embodiments described above and illustrated in the figures are presented by way of example only and are not intended as a limitation upon the concepts and principles of the present invention. As such, it will be appreciated by one having ordinary skill in the art that various changes in the elements and their configuration and arrangement are possible without departing from the spirit and scope of the present invention. 

1. A body support comprising a foam layer having a substantially planar bottom surface and a smooth, non-planar top surface with a plurality of peaks and troughs that run in succession along an entire length of the body support, wherein only two of the plurality of peaks have an adjacent trough on each side thereof, and wherein an additional two of the plurality of peaks have an adjacent trough on only one side thereof.
 2. A body support as defined in claim 1, wherein the foam comprises visco-elastic foam.
 3. A body support as defined in claim 1, wherein the peaks and troughs of the non-planar top surface form sinusoidal waves.
 4. A body support as defined in claim 1, wherein the peaks and troughs of the non-planar top surface form domed waves.
 5. A body support as defined in claim 1, wherein a density of the foam at the peaks is substantially the same as the density of the foam at the troughs.
 6. (canceled)
 7. (canceled)
 8. (canceled)
 9. A body support as defined in claim 1, wherein the peaks and valleys define a horizontal distance between peaks and a vertical height between a peak and a trough, and wherein a ratio of the distance to the height is from 13 to
 66. 10. (canceled)
 11. (canceled)
 12. (canceled)
 13. (canceled)
 14. A body support as defined in claim 9, wherein the ratio of the distance to the height is from 20 to
 52. 15. A body support as defined in claim 9, wherein the ratio of the distance to the height is from 26 to
 40. 16. A body support as defined in claim 9, wherein the ratio of the distance to the height is from 26 to
 33. 